Patent Application
20140222292
Larger vehicles require significant force to turn the wheels during a steering action. It is difficult to provide the power required to produce this force using current controller technology. In the event of a controller shutdown, the loss of power steering assist would require more effort from the driver to steer the vehicle. The inadequate power steering assist is undesirable and may lead to poor consumer satisfaction and a perceived lack of quality.
In accordance with the invention, a vehicle electric power steering (EPS) control system includes a motor operatively coupled to an EPS linkage arrangement, the motor comprising a first winding and a second winding. Also included is a power source for the motor and EPS control system. Further included is a controller in operative communication with the motor and the power source. The controller includes a microprocessor configured to receive input from a torque sensor and a motor sensor. The EPS controller also includes a first field-effect transistor (FET) driver in operative communication with the microprocessor and a first plurality of FETs operatively connected to the first winding of the motor. The EPS controller a second FET driver in operative communication with the microprocessor and a second plurality of FETs operatively connected to the second winding of the motor.
In accordance with another embodiment of the invention, a vehicle electric power steering (EPS) control system includes a motor operatively coupled to an EPS linkage arrangement, the motor comprising a first winding and a second winding. Also included is a power source configured to power the first winding and the second winding of the motor. Further included is a first electronic control unit (ECU) in operative communication with the power source and the first winding of the motor. The first ECU includes a first microprocessor configured to receive input from a first torque sensor and a first motor sensor. The first ECU also includes a first field-effect transistor (FET) driver in operative communication with the first microprocessor and a first plurality of FETs operatively connected to the first winding of the motor. The EPS control system yet further includes a second ECU in operative communication with the power source and the second winding of the motor. The second ECU includes a second microprocessor configured to receive input from a second torque sensor and a second motor sensor. The second ECU also includes a second field-effect transistor (FET) driver in operative communication with the second microprocessor and a second plurality of FETs operatively connected to the second winding of the motor.
These and other advantages and features will become more apparent from the following description taken in conjunction with the drawings.
The subject matter which is regarded as the invention is particularly pointed out and distinctly claimed in the claims at the conclusion of the specification. The foregoing and other features, and advantages of the invention are apparent from the following detailed description taken in conjunction with the accompanying drawings in which:
Referring now to the Figures, where the invention will be described with reference to specific embodiments, without limiting same, the disclosed invention provides steering assist in a steering system required to provide high assist torque even when a system fault occurs.
Referring to
The steering system 10 includes numerous components, such as various linkage members, sensors, switches, and accessories. The steering system 10 transfers rotation and torque from an input member, such as a steering wheel assembly (not illustrated) to an output member, such as one or more wheels 12. The steering wheel assembly is operatively coupled to a linkage arrangement 14 of the steering system 10 with a first shaft 16, which may be referred to as a pitman shaft. The wheels 12 of the vehicle are turned through movement of the linkage arrangement 14 and, more particularly, though movement of a cross-link member 18. The cross-link member 18 extends in a substantially transverse direction relative to vehicle travel, i.e. cross-car direction of the vehicle, and translates in this direction as well. Translation of the cross-link member 18 imparts movement of numerous other components that link the cross-link member 18 to the wheels 12 of the vehicle. Such intermediary components include a first tie rod 20 rotationally coupled to the cross-link member 18, as well as one or more additional linkage members 22 and a first steering knuckle 24 that pivots with respect to a frame of the vehicle. Similarly, a second tie rod 26 is rotationally coupled to the cross-link member 18 and is indirectly coupled to a wheel of the vehicle with a linkage member 28 and a second steering knuckle 30 that pivots with respect to the frame of the vehicle.
In the illustrated embodiment, the linkage arrangement 14 includes a first linkage arm 32 that is pivotally coupled to the cross-link member 18 at a location proximate the first shaft 16. The first linkage arm 32 is pivotally coupled to the frame of the vehicle via a first pivot joint 34 and is free to rotate in response to an input from the first shaft 16. A second linkage arm 36 is also pivotally coupled to the cross-link member 18 at a pivot location 38. The second linkage arm 36 is pivotally coupled to the frame of the vehicle via a second pivot joint 40 and is free to rotate.
A linkage member 44 extends from an electric motor 48 that is operatively coupled to the frame of the vehicle. The operative coupling of the electric motor 48 comprises a pivotal connection via a pivot joint 50. In the illustrated embodiment, the electric motor 48 is configured to translate the linkage member 44 in a substantially linear manner in the direction of the arrow shown in
It is to be appreciated that the above-described linkage arrangement is merely exemplary and various alternative linkage arrangements may be employed in association with the control system described in detail herein.
Referring now to
The controller 62 includes at least one, but typically a first plurality of power devices 70 electrically connected to the power input 64 and also connected to a first winding 72 of the electric motor 48. In operation, the first power devices 70 receive electrical power and variably provide the electrical power to the electric motor 48. In one embodiment, the first power devices 70 are inverter field-effect transistors (FETs), such as MOSFETs or some other suitable alternative power device. A first driver 74 is electrically connected to the first power devices 70 for regulating the operation of, and electric power provided to, the first power devices 70. By regulating the electric power provided to the first power devices 70, the first driver 74 regulates the electric power provided to the electric motor 48. The electric power is often provided in a variable manner that changes the amount of power steering assist provided by the electric motor 48, depending on certain vehicle conditions, as described herein.
The controller 62 also includes a microprocessor 76 electrically connected to the first driver 74 for controlling the first driver 74. Control of the first driver 74 is based on at least one signal input to the microprocessor 76 for regulating the amount of power supplied by the first power devices 70 to the electric motor 48. In one embodiment, the microprocessor 76 is a dual-core processor, but it is to be understood that suitable alternative processing devices may be employed. As noted above, the microprocessor 76 includes one or more signal inputs for power regulation purposes. These inputs include, but are not limited to, the electric current flowing through the first power devices 70, the speed of the electric motor 48, the positioning of a rotor of the electric motor 48, and the speed of the vehicle.
To provide a signal corresponding to the current flowing through the first power devices 70, the controller 62 includes at least one first current sensor 78 electrically connected to the first power devices 70. In the illustrated embodiment, two first current sensors are included to detect the current flowing through the first power devices 70. The first current sensor(s) 78 are in operative communication with the microprocessor 76. More specifically, the first current sensor(s) 78 are electrically connected to the microprocessor 76.
To provide a signal related to the torque applied at the steering column of the steering system 10, a torque sensor 80 is included. In the exemplary embodiment of the linkage arrangement 14 of
To provide redundancy for the steering system 10, the controller 62 includes a duplicative sub-system that may be referred to as a redundant, or secondary, sub-system. The components described in detail above may be referred to as a primary sub-system. It is to be appreciated that the primary sub-system and the redundant sub-system include overlapping components and are differentiated by duplicative components that include, but are not limited to, the second winding 84 of the electric motor 48, one or more second power devices 86, a second driver 88 and one or more second current sensors 90. In this system, both sub-systems would operate simultaneously, with each providing a portion of the overall power to the system. If one sub-system can no longer operate correctly, the other sub-system can continue to operate, providing a reduced level of total performance.
The second power devices 86 are electrically connected to the power input 64 and to a second winding 84 of the electric motor 48. In operation, the second power devices 86 receive electrical power and variably provide the electrical power to the electric motor 48. In one embodiment, the second power devices 86 are inverter field-effect transistors (FETs), such as MOSFETs or some other suitable alternative power device. The second driver 88 is electrically connected to the second power devices 86 for regulating the operation of, and electric power provided to, the second power devices 86. By regulating the electric power provided to the second power devices 86, the second driver 88 regulates the electric power provided to the electric motor 48. The electric power is often provided in a variable manner that changes the amount of power steering assist provided by the electric motor 48, depending on certain vehicle conditions, as described herein.
The microprocessor 76 is electrically connected to the second driver 88 for controlling the second driver 88. Control of the second driver 88 is based on at least one signal input to the microprocessor 76 for regulating the amount of power supplied by the second power devices 86 to the electric motor 48. As described above, the microprocessor 76 includes one or more signal inputs for power regulation purposes. These inputs include, but are not limited to, the electric current flowing through the second power devices 86, the speed of the electric motor 48, the positioning of a rotor of the electric motor 48, and the speed of the vehicle.
To provide a signal corresponding to the current flowing through the second power devices 86, the controller 62 includes the second current sensor(s) 90 that is electrically connected to the second power devices 86. In the illustrated embodiment, two second current sensors are included to detect the current flowing through the second power devices 86. The second current sensor(s) 90 are in operative communication with the microprocessor 76. More specifically, the second current sensor(s) 90 are electrically connected to the microprocessor 76.
As described above, a signal related to the position of the electric motor 48 is provided by a motor sensor 82 in operative communication with the electric motor 48. The motor sensor 82 is configured to detect and communicate to the microprocessor 76 the position of the first winding 72 and the second winding 84.
The controller 62 also includes a voltage regulator 92 that is in operative communication with the battery 68 and is configured to regulate and selectively route electric power to the primary sub-system and the redundant sub-system. The voltage regulator 92 is electrically connected to various components of the primary sub-system and the redundant sub-system.
In the above-described embodiment, the electric motor 48 comprises a dual winding motor and the overall control system includes dual motor control power devices (e.g., first and second power devices 70, 86). The electric motor 48 effectively comprises two three-phase motors available for powering electric assist to the linkage arrangement 14 of the steering system 10. Dual control with the addition of the redundant sub-system facilitates power steering assist in the event of failure of the first power devices 70 (i.e., first inverter set) and allows for more effective management of the thermal system losses by spreading the heat between two inverter groups.
Referring now to
In the illustrated embodiment, the steering system 100 includes a control system 110 for the steering system 100 and, more specifically, the linkage arrangement 14 of the steering system 100. The control system 110 includes a primary sub-system 112 that includes a first electronic control unit (ECU) 114 for controlling the electrical power supplied to the electric motor 48. The first ECU 114 includes a first power input 116 for receiving electrical power. Typically, the electrical power is supplied from one or more batteries 118 and has a voltage. As noted above, current vehicle applications utilize 12 V systems. However, those skilled in the art should readily appreciate that other sources of the electrical power in the vehicle may be implemented and that other voltages may alternatively be suitable.
The first ECU 114 includes at least one, but typically a first plurality of power devices 120 electrically connected to the first power input 116 and to a first winding 122 of the electric motor 48. In operation, the first power devices 120 receive electrical power and variably provide the electrical power to the electric motor 48. In one embodiment, the first power devices 120 are inverter field-effect transistors (FETs), such as MOSFETs or some other suitable alternative power device. A first driver 124 is electrically connected to the first power devices 120 for regulating the operation of, and electric power provided to, the first power devices 120. By regulating the electric power provided to the first power devices 120, the first driver 124 regulates the electric power provided to the electric motor 48. The electric power is often provided in a variable manner that changes the amount of power steering assist provided by the electric motor 48, depending on certain vehicle conditions, as described herein.
The first ECU 114 also includes a first microprocessor 126 electrically connected to the first driver 124 for controlling the first driver 124. Control of the first driver 124 is based on at least one signal input to the first microprocessor 126 for regulating the amount of power supplied by the first power devices 120 to the electric motor 48. In one embodiment, the first microprocessor 126 is a dual-core processor, but it is to be understood that suitable alternative processing devices may be employed. As noted above, the first microprocessor 126 includes one or more signal inputs for power regulation purposes. These inputs include, but are not limited to, the electric current flowing through the first power devices 120, the speed of the electric motor 48, the positioning of a rotor of the electric motor 48, and the speed of the vehicle.
To provide a signal corresponding to the current flowing through the first power devices 120, the first ECU 114 includes at least one first current sensor 128 electrically connected to the first power devices 120. In the illustrated embodiment, two first current sensors are included to detect the current flowing through the first power devices 120. The first current sensor(s) 128 are in operative communication with the first microprocessor 126. More specifically, the first current sensor(s) 128 are electrically connected to the first microprocessor 126.
To provide a signal related to the torque applied at the steering column of the steering system 100, a first torque sensor 130 is included. In the exemplary embodiment of the linkage arrangement 14 of
The first ECU 114 also includes a first voltage regulator 134 that is in operative communication with the battery 118 and is configured to regulate and selectively route electric power to the primary sub-system, specifically including the first driver 124, the first microprocessor 126 and the first current sensor(s) 128, among other potential components.
As noted above, complete redundancy of the control system 110 is achieved with a duplication of the components of the primary sub-system. Specifically, the control system 110 includes a redundant sub-system 142 that includes a second electronic control unit (ECU) 144 for controlling the electrical power supplied to the electric motor 48. The second ECU 144 includes a second power input 146 for receiving electrical power. Typically, the electrical power is supplied by the battery 118 and has a voltage. Once again, current vehicle applications utilize 12 V systems. However, those skilled in the art should readily appreciate that other sources of the electrical power in the vehicle may be implemented and that other voltages may alternatively be suitable.
The second ECU 144 includes at least one, but typically a second plurality of power devices 150 electrically connected to the second power input 146 and to the second winding 132 of the electric motor 48. In operation, the second power devices 150 receive electrical power and variably provide the electrical power to the electric motor 48. In one embodiment, the second power devices 150 are inverter field-effect transistors (FETs), such as MOSFETs or some other suitable alternative power device. A second driver 154 is electrically connected to the second power devices 150 for regulating the operation of, and electric power provided to, the second power devices 150. By regulating the electric power provided to the second power devices 150, the second driver 154 regulates the electric power provided to the electric motor 48. The electric power is often provided in a variable manner that changes the amount of power steering assist provided by the electric motor 48, depending on certain vehicle conditions, as described herein.
The second ECU 144 also includes a second microprocessor 156 electrically connected to the second driver 154 for controlling the second driver 154. Control of the second driver 154 is based on at least one signal input to the second microprocessor 156 for regulating the amount of power supplied by the second power devices 150 to the electric motor 48. In one embodiment, the second microprocessor 156 is a dual-core processor, but it is to be understood that suitable alternative processing devices may be employed. As noted above, the second microprocessor 158 includes one or more signal inputs for power regulation purposes. These inputs include, but are not limited to, the electric current flowing through the second power devices 150, the speed of the electric motor 48, the positioning of a rotor of the electric motor 48, and the speed of the vehicle.
To provide a signal corresponding to the current flowing through the second power devices 150, the second ECU 144 includes at least one second current sensor 158 electrically connected to the second power devices 150. In the illustrated embodiment, two second current sensors are included to detect the current flowing through the second power devices 150. The second current sensor(s) 158 are in operative communication with the second microprocessor 156. More specifically, the second current sensor(s) 158 are electrically connected to the second microprocessor 156.
To provide a signal related to the torque applied at the steering column of the steering system 100, a second torque sensor 160 is included. In the exemplary embodiment of the linkage arrangement 14 of
The second ECU 144 also includes a second voltage regulator 164 that is in operative communication with the battery 118 and is configured to regulate and selectively route electric power to the redundant sub-system, specifically including the second driver 154, the second microprocessor 156 and the second current sensor(s) 158, among other potential components.
In addition to two completely distinct ECUs, the components of each sub-system could be physically located on one printed circuit board (PCB) with separated copper layers.
In all of the embodiments described above, the electric motor 48 contains a rotor shaft with magnets and a stator wound with coils for two independent sets of a three-phase motor. In one embodiment, the electric motor 48 comprises a 12-slot, eight-pole configuration, with the 12 poles schematically illustrated in
Advantageously, the above-described embodiments provide steering assist torque to each independent winding in the electric motor 48 from their respective sub-systems (i.e., primary and redundant sub-systems). Each ECU 114, 144 is configured to diagnose its own sub-system faults and react accordingly. In the event an ECU fails to operate, the other ECU and its components will remain operational in a normal manner to provide steering assist for the driver to safely operate the vehicle. The redundant ECUs and dual wound motor provide reliability such that no single controller or sensor fault causes a complete loss of steering assist.
As described above, the sub-systems of the above-described embodiments include separate and isolated components that reduce or eliminate the possibility of one adversely impacting the other. In one embodiment, each sub-system provides about 50% of the power steering assist at normal operation. In other embodiments, one of the sub-systems provides the majority of the power steering assist. Based on this, the terms primary and secondary (or redundant) may represent which provides more power, but it is to be understood that the sub-systems can operate simultaneously and continue to do so if the other sub-system fails. This is distinct from a system that includes a “back-up” system that only begins to operate in the event of failure of another sub-system.
By providing a sub-system with duplication of some or all components of another sub-system, the EPS control system described herein facilitates a simple transition during a failure mode that allows a vehicle operator to maneuver the vehicle to safety with little noticeable impact to the driver. In addition, the dual wound motor system of the invention provides significant advantages when used in high load EPS applications, such as light or heavy duty trucks. A dual wound motor system is significantly less expensive than a single wound system capable of handling the same static and dynamic steering loads. It has the added advantage of providing the redundant or “back-up” system capability when one or the other system fails to operate. The Integration of the above-described embodiments with a dual wound motor is unique to an EPS system Both systems provide simultaneous steering assist which has particular utility in both cost effectiveness and redundancy for a high load system.
While the invention has been described in detail in connection with only a limited number of embodiments, it should be readily understood that the invention is not limited to such disclosed embodiments. Rather, the invention can be modified to incorporate any number of variations, alterations, substitutions or equivalent arrangements not heretofore described, but which are commensurate with the spirit and scope of the invention. Additionally, while various embodiments of the invention have been described, it is to be understood that aspects of the invention may include only some of the described embodiments. Accordingly, the invention is not to be seen as limited by the foregoing description.
This patent application claims priority to U.S. Provisional Patent Application Ser. Nos. 61/761,480 and 61/761,477, both filed Feb. 6, 2013, both of which are incorporated herein by reference in their entirety.
| Number | Date | Country | |
|---|---|---|---|
| 61761480 | Feb 2013 | US | |
| 61761477 | Feb 2013 | US |
